Acoustical system



March 22, 1966 w. G. KEMP ACOUSTICAL SYSTEM med Ap1-11 21, 1961 UnitedStates Patent O 3,241,232 ACIUSTICAL SYSTEM William G. Kemp, Pontiac,Mich., assigner to The Soundlock Corporation, Hazelhurst, Ga., acorporation of Delaware Filed Apr. 21, 1961, Ser. No. 104,725 11 Claims.(Cl. 52--485) This invention relates generally to ceiling structure andrefers more particularly to an acoustical ceiling structure composed ofindividual separable panels.

One object of this invention is to provide a ceiling structure composedof individual separable panels arranged edge to edge and in the sameplane to form a continuous ceiling, the panels having an edge to edgesupporting engagement with each other designed to facilitate assemblyand disassembly.

Another object is to provide an acoustical ceiling structure in whichadjacent panels have an upwardly extending flange on the edge of one anda downwardly opening channel-shaped hook on the edge of another engagedover and supported on the flange.

Another object is to provide an acoustical ceiling structure in whichthe panels are arranged in laterally spaced rows, the panels inalternate rows each having at one end edge an upwardly extending flangeand at the opposite end edge a downwardly opening hook engaged over andsupported by the flange of the adjacent panel in the same row.

Another object is to provide an acoustical ceiling structure wherein thepanels in the alternate rows have upwardly extending flanges at theopposite side edges thereof, and the panels in the remaining rows havedownwardly opening hooks at the opposite side edges respectively engagedover and supported by the side flanges of the adjacent panels in thealternate rows. This construction enables one man installation andmaintains the panels in straight rows without zig-Zag.

Another object is to provide support means in the form of suspensionhangers for the flanged ends of the panels in the alternate rows.

Another object is to provide sealing material in the base of each hookto be engaged by the edge of the flange received therein.

Another object is to provide a hook construction for the panel edgeswherein the ends of the hooks are turned out or an entire wall of thehook is inclined from the base thereof from the opposite wall, for thepurpose of facilitating the entry of a flange and to dra'w the panelstogether.

Other objects and features of the invention will become more apparent asthe following description proceeds, especially when considered with theaccompanying drawing, wherein:

FIGURE 1 is a bottom plan view of a ceiling structure according to myinvention.

FIGURE 2 is a line diagram of the ceiling structure shown in FIGURE 1,in end elevation.

j FIGURE 3 is a line diagram in side elevation.

FIGURE 4 is an enlarged sectional view of a portion of FIGURE 2.

Referring now more particularly to the drawing, the ceiling structure isgenerally indicated by the reference numeral and is composed ofindividual separable rectangular acoustical panels 12 and 14. As viewedin FIGURE 1, the panels 12 are arranged in the alternate rows A and thepanels 14 are arranged in the rows B between the rows A.

The panels 12 are identical and each has a sheet metal front facing 16and a sheet metal rear facing 18 which is parallel to and spaced behindthe front facing. The front facing is perforated and a honeycombstructure 20 3,241,282 Patented Mar. 22, 1966 is sandwiched between thefacings. The honeycomb may be formed of a cardboard material and,together with the facings 16 and 18, provides a strong compositestructure which resists bending or twisting. A heat insulating and soundabsorbing material 22, which may be formed of glass, wool or woodfibers, fills the cells of the honeycomb 20. The margins of the backfacing 18 of each panel 12 are turned at right angles toward the frontfacing 16 to define the parallel ends 24 and 26 and the parallel sides28 and 30.

A supporting portion 32 is provided along the opposite side edges ofeach panel 12. A similar supporting portion 32 is also provided alongone end edge of each panel 12. The supporting portions are formed bysurface-tosurface extensions of the front and back facings. Referring toFIGURE 4, the supporting portion 32 there shown is formed by thesurface-to-surface integral lateral extensions of the front and backfacings 16 and 18 respectively beyond the side 28. Thesesurface-to-surface extensions project laterally outwardly in the planeof the front facing and are then turned at right angles to the plane ofthe front facing toward the back facing to provide an upright flange 34parallel to the side 28. The flange forming metal of the front facing 16extends over the end of the ange forming metal of the back facing 1.8and along the opposite side thereof and continues along that part of thesupporting portion 32 which is parallel to the plane of the front facing16 so that the supporting portion 32 is formed of three layers of metalin surface-to-surface contact for strength and rigidity. The supportingportion 32 along the opposite side 30 of each panel 12 is identical tothe one shown in FIGURE 4 and projects from said opposite side 30 of thepanel, and the end supporting portion 32 of each panel 12 is alsoidentical to that shown in FIGURE 4, projecting outwardly from the endwall 26.

The remaining end edge of each panel 12 is provided with a marginalextension in the form of a supported portion 40. This is a hook portion,and since identical hook portions 40 are provided on each panel B, oneof which is shown in the enlarged View of FIGURE 4, reference will bemade to FIGURE 4 to describe this supported portion. As shown in FIGURE4, lthe supported portion 40 is formed by integral extensions of thefront and back facings 16 and 18 beyond the corresponding end or side ofthe associated panel 12. These extensions of the front and Iback facingsare in surface-to-surface contacting relation with each other and extendlaterally outwardly from the panel in the plane of the front facing 16,then turn at right angles toward the back facing 18 and parallel to thefront or end wall of the panel to form an upright flange 42 which isreturn bent to form a hook 44 the opposite flange of which is indicatedat 46 and terminates in a turned-out end 48. It will be noted that themetal of the back facing 18 continues beyond the end 48 and along theopposite surface of the metal formed as an extension of the front facing16 to provide a triple layer o-f metal for the flange 46 of the hook.The remainder of the supported portion 40 is in two layers. Preferably,and as shown in FIGURE 4, the lflange 46 of the hook 44 is inclined fromthe base of the hook away from the flange 42.

It will be understood that the supporting portions 32 extend for thefull length of the side edges and one end edge of each panel 12, andthat the supported portion 40 likewise extends for the full length ofthe opposite end edge thereof.

The panels 14 are identical with the `panels 12 except for the marginsthereof, each panel 14 having at the side edges and one end edge asupported portion 40, and at the opposite end edge a supporting portion32.

A T-shaped member 50 is secured to each side edge of each panel 12 nearthe the end thereof having the supporting portion 32. The stems 52 ofthe T-shaped members Sil are rigidly secured in surface-to-surfacerelation to the sides 28 and 30 of each panel 12. A generallychannel-shaped resilient clip 54 is associated with each T-shapedmember, the clips 54 being suspended from an overhead ceiling structure.The clips 54 are thus suspended by rods 56 which together with the clipsform suspension hangers. The legs of the clips are shaped to provideopposed channels 58 and terminate at their lower ends in flanges 60.Hence the cross member 62 of the T may be snapped into the opposedrecesses or channels 58 of the associated clip by merely pressingupwardly to cam the legs apart by engagement with the flanges 60. Thecross members `62 of the T-shaped members are in off-center relationwith respect to the stems in order to clear the hook and flangeconnection between adjacent panels.

In order t0 install the acoustical ceiling structure, and assuming thesuspension hangers composed of the rods 56 and clips 54 are in place,the row A of panels 12 are first put up. This is accomplished byengaging the hook 44 of the supported portion 40 along one end of eachpanel 12 over the flange 34 of the supported portion 32 along theadjacent end of the next `panel in the row. Then the end of the panel 12having the iianged or supported portion 32 is engaged with the clip 54of the adjacent hanger by means of the T-shaped member Si). The nextpanel in the row is then installed in the same manner, that is, its hookshaped end is engaged over the flanged end of the installed panel, andits flanged end is then suspended from the associated clip 54. The rstpanel 12 to be installed in the row A may be supported by laying on asuitable ange provided by a wall angle or channel fixed to the wall ofthe enclosure.

Alternate rows A are installed in this manner, and then the panels 14 ofthe rows B are installed to complete the ceiling structure. The panels14 are installed in the rows B by turning them edge-wise to elevate themabove the level of the common horizontal plane established by theinstalled rows A of panels 12, and then panels 14 are lowered so thatthe hooks along their sides engage over and are supported on the flanges34 of the panels 12 in the rows A. As each panel 14 is installed, itsend having the hook 44 is engaged over the flange of the end of a Bpanel previously installed. The first panel 14 to be installed in B rowsmay be supported by laying on a suitable iiange provided by a wall orchannel fixed to the wall of the enclosure.

By reason of the inclined wall 46 of each hook and the turned-outterminal portion 48 thereof, itt will be apparent that the hooks 44 maybe readily engaged over the associated iianges. Moreover, a lead-in isthereby provided to firmly engage the flange in the base of the hook andto draw the panels together `by the movement of the flange .along theinclined wall 46 to the narrow base of the hook during installation.

Preferably a strip of sealing material 71B fills the base of each hook44 along the full length thereof to be engaged by the flange receivedtherein to provide a seal against the transmission of air and also 'toprovide a sound barrier.

As shown in FIGURE 4, the panel extensions forming the portions 32 and40 are rounded as indicated at 75 in order to avoid lthe appearance ofany sharp edges or shadows which might result from a small degree ofmisalignment of the panels.

According to this construction, the panels together form a continuousceiling structure and are disposed in edge-to-edge relationship in thesame plane. As viewed from below, the front facings 16 are coplanar andany misalignment of panels is minimized from the standpoint ofappearance by the bevel along the meeting edges. Moreover, the panels inthe rows B being supported by the panels in the rows A can be readilyremoved by simply lifting them from hook engagement, turning themedgewise and then lowering them through the opening between the otherpanels for access to the area above the ceiling. The panels are veryrigid because of the sandwich construotion provided by the front andback facings and intermediate honeycomb core, and the marginal portions32 and 4i) are also extremely strong, being composed of two and threelayers of metal.

One man can install this ceiling. When putting up the A rows, the hookedend of one panel is engaged over the flange of another, and the hookedend is thus supported while the flanged end is connected to a clip 54.The B panels can also be installed `by one man in the manner describedabove.

The B panels tie together the A panels in side by side relationstabilizing and rigidifying the entire ceiling and preventing the panelsfrom spreading apart. The hooked connection between panels also keep-sthem in straight rows without zig-zag.

What I claim as my invention is:

1. In a ceiling structure, a plurality of individual, separable,rectangular, acoustical panels arranged substantially in edge-to-edgerelation in a common horizontal plane in parallel rows to form acontinuous ceiling, the panels in alternate rows each having at one endedge an upwardly extending flange and at the opposite edge a downwardlyopening hook straddling the flange of the adjacent panel in the samerow, said panels in the alternate rows having upwardly extending flangesat the opposite side edges thereof, and the panels in the remaining rowshaving downwardly opening hooks at the opposite side edges thereofrespectively straddling the side flanges of the adjacent panels in saidalternate rows.

2. The ceiling structure defined in claim 1, wherein the panels in saidremaining rows each have at one end edge an upwardly extending flangeand at the opposite edge a downwardly opening hook straddling the flangeof the adjacent panel in the same row, the hook and flange connectionbetween panels enabling one man installation and being effective tomaintain the panels in straight rows, and support means for the flangedends of the panels in said alternate rows.

3. In a ceiling structure, a plurality of individual, separable,rectangular, acoustical panels arranged substantially in edge-to-edgerelation in a common horizontal plane and in parallel rows to form acontinuous ceiling, the panels in alternate rows each having at one endedge a horizontally extending supporting portion projecting outwardlytherefrom and provided with an upright portion substantially parallel tothe adjacent end edges of said panels, the panels in said alternate rowseach having at the opposite end edge a horizontally extending supportedportion projecting outwardly therefrom and provided with an uprightportion substan-tially parallel to the adjacent end edges of said panelsand disposed in surface-to-surface engagement with the upright portionof the supporting portion of the adjacent panel in the same row, theupright portion of each said supported portion having a downwardlyopening return-bent portion constituting a hook straddling the uprightportion with which it is disposed in surface-to-surface engagement, saidpanels in alternate rows having at each side edge thereof a horizontallyextending supporting portion projecting outwardly therefrom and providedwith an upright portion substantially parallel to the adjacent sideedges of said panels, the panels in the remaining rows having at eachside edge thereof a horizontally extending supported portion projectingoutwardly therefrom and provided with an upright portion substantiallyparallel to the adjacent side edges of said panels and disposed insurface-to-surface engagement with the upright portion of saidsupporting portion on the side edge of a panel in the adjacent alternaterow, the upright portion of each said supported portion on the sideedges of the panels in said remaining rows having a downwardly openingreturn-bent portion constituting a hook straddling the upright portionwith which it is disposed in surface-tosurface engagement.

4. In a ceiling structure, a plurality of individual, separable,rectangular, acoustical panels arranged substantially in edge-to-edgerelation in a common horizontal plane and in parallel rows to -form acontinuous ceiling, said panels having front and back facings, eachpanel having at one end edge a horizontally extending supporting portionprojecting outwardly therefrom and provided with an upright portionsubstantially parallel to the adjacent end edges of said panels, eachpanel having at the opposite end edge a horizontally extending supportedportion projecting outwardly therefrom and provided with an uprightportion substantially parallel to the adjacent end edges of said panelsand disposed in surface-to-surface engagement with the upright portion-of the supporting portion of the adjacent panel in the same row, theupright portion of each said supported portion having a downwardlyopening return-bent portion constituting a lhook straddling the uprightportion with which it is disposed in surface-to-surface engagement,means suspending the panels in said alternate rows near the ends thereofhaving said supporting portions, said panels in alternate rows having ateach side edge thereof a horizontally extending supporting portionprojecting outwardly therefrom and provided with an upright portionsubstantially parallel to the adjacent side edges of said panels, thepanels in the remaining rows having at each side edge thereof ahorizontally extending supported portion projecting outwardly therefromand provided with an upright portion substantially parallel to theadjacent side edges of said panels and disposed in surface-to-surfaceengagement with the upright portion -of said supporting portion on theside edge of a panel in the adjacent alternate row, the upright portionof each said supported portion on the side edges of the panels in saidremaining rows having a downwardly opening return-bent portionconstituting a hook straddling the upright portion with which it isdisposed in surface-to-surface engagement, said supporting portionsincluding the upright portions thereof being formed from extensions ofsaid front and back panel facings arranged in surface-to-surfacerelation with each other, said supported portions including the uprightportions thereof as well as said return-bent portions being formed fromextensions of said front and back panel facings arranged insurface-to-surface relat1on with each other, said supporting andsupported portions projecting laterally from said respective panels insubstantially the horizontal plane of the front facings of said panels.

5. The ceiling structure defined in claim 4, wherein said suspendingmeans comprises a pair of T-shaped mem- 'bers for each panel in thealternate rows, each T-shaped member projecting above and having thestem thereof secured to a side edge of a panel in an alternate rowadjacent the end thereof having the supporting portion, a clip suspendedfrom an overhead ceiling structure connected to the cross-member of eachT-shaped member, said cross-member of each T-shaped member being inoff-center relation with respect to the stem thereof so that the portionof said cross-member projecting laterally outward with respect to thepanel by which it is carried is shorter than the inwardly projectingportion thereof, -to clear the connection between panels in adjacentrows.

6. The acoustical structure defined in claim 5, wherein sealing materialfills the bight of each hook and cooperates with the upper edge of theupright portion it straddles to provide a seal.

7. In a ceiling structure, individual, separable, rectangular,acoustical panels arranged substantially in edgeto-edge relation in acommon horizontal plane, each panel having a flat perforated memberdening its bottom surface, and mean-s providing -a connection betweenadjacent edges of said panels including a horizontally extendingsupporting portion projecting from one of said panels and having anupright portion substantially parallel to the adjacent edges of saidpanels, and a horizontally extending supported portion projecting fromthe other of said panels and having an upright portion substantiallyparallel to the adjacent edges of said panels and disposed insurface-to-surface engagement with the upright portion of saidsupporting portion, the upright portion of said supported portion havinga downwardly opening returnbent portion constituting a hook straddlingthe upright portion of said supporting portion, said supported andsupporting portions being formed a-t least in part from extensions ofsaid perforated members, said extensions being disposed in thehorizontal plane of the perforated members of said panels.

8. In a ceiling structure, individual,l separable, rectangular,acoustical panels arranged substantially in edgeto-edge relation in acommon horizontal plane, said panels having front and back facings, andmeans providing a connection between adjacent edges of said panelsincluding a horizontally extending supporting portion projecting fromone of said panels and having an upright portion substantially parallelto the adjacent edges of said panels, and -a horizontally extendingsupported portion projecting from the other of said panels and having anupright portion substantially parallel to the adjacent edges of saidpanels and `disposed in surface-to-surf-ace engagement with the uprightportion of said supporting portion, the upright portion of saidsupported portion having a downwardly opening return-bent portionconstituting a hook straddling the upright portion of said supportingportion, said supporting portion and upright portion thereof beingformed from extensions of said facings of said one panel arranged in`surface-to-surface relation with each other, said supported portion andthe upright portion thereof as well as said return-bent portion beingformed from extensions of said facings of said other panel arranged insurface-tosurface relation with each other, said supporting andsupported portions projecting laterally from the respective panels insubstantially the horizontal plane of the front facings of said panels.

9. The ceiling structure defined in claim 8, wherein sealing materialiills the bight of each hook and cooperates with the upper edge of theupright portion of the supporting portion to provide a seal.

10. In a ceiling structure, individual, separable, rectangular,acoustical panels arranged substantially in edgeto-edge relation in acommon horizontal plane, each panel having a `substantially flatperforated member, a substantially at second member extending over saidperforated member in spaced, parallel relation thereto, and a relativelyrigid honeycomb core between said members to resist warping, and meansproviding a connection between adjacent edges of said panels including asupporting portion projecting from one of said panels and having anupright portion substantially parallel to the adjacent edges of saidpanels, and a supported portion projecting from the other of said panelsand having an upright portion substantially parallel to the adjacentedges of said panels and disposed in close parallel, opposed relationwith the upright portion of said supporting portion, the uprightpor-tion of said supported portion having a downwardly openingreturn-bent portion constituting a hook straddling the upright portionof said supporting portion, said supporting portion and upright portionthereof being formed from an extension of at least one of said membersof said one panel, said supported portion and the upright portionthereof as well as said return-bent portion being formed from anextension of at least one of said members of said other panel, saidsupporting and supported portions projecting laterally from therespective panels in substantially the horizontal plane of theperforated members of said panels.

7 8 1l. The ceiling structure defined in claim 10, wherein ReferencesCited bythe Examiner each of said' panels is proxfidedelong ltheOpposite edges UNITED STATES PATENTS thereof contlguous with saidadlacent edge with laterally Outward extensions to support Asaid panelsin a ceiling 11249362 12/1917 Ferguson w- 52536 structure, saidlaterally outward extensions being formed 5 219941113 8/1961 D311 52-484from integral extended portions of at least one of said members- RICHARDW. COOKE, IR., P/zmary Examzner.

1. IN A CEILING STRUCTURE, A PLURALITY OF INDIVIDUAL, SEPARABLE, RECTANGULAR, ACOUSTICAL PANELS ARRANGED SUBSTANTIALLY IN EDGE-TO-EDGE RELAITON IN A COMMON HORIZONTAL PLANE IN PARALLEL ROWS TO FORM A CONTINUOUS CEILING, THE PANELS IN ALTERNATE ROWS EACH HAVING AT ONE END EDGE AN UPWARDLY EXTENDING FLANGE AND AT THE OPPOSITE EDGE A DOWNWARDLY OPENING HOOK STRADDLING THE FLANGE OF THE ADJACENT PANEL IN THE SAME ROW, SAID PANELS IN THE ALTERNATE ROWS HAVING UPWARDLY EXTENDING FLANGES AT THE OPPOSITE SIDE EDGES THEREOF, AND THE PANELS IN THE REMAINING ROWS HAVING DOWNWARDLY OPENING HOOKS AT THE OPPOSITE SIDE EDGES THEREOF RESPECTIVELY STRADDLING THE SIDE FLANGES OF THE ADJACENT PANELS IN SAID ALTERNATE ROWS. 